Mattress with customized density

ABSTRACT

An exemplary aspect of the present disclosure relates to a mattress and a method for manufacturing a mattress. The method includes, among other things, providing a batt of polymer fibers with a reduced dimension, forming a topper layer of polymer fibers having a lower surface corresponding to the reduced dimension in the batt, and arranging the topper layer relative to the batt such that the lower surface of the topper layer mates with the reduced dimension in the batt.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/018,918, filed Jun. 30, 2014, the entirety of which is herein incorporated by reference.

BACKGROUND

Mattresses are known to include a combination of springs and foam padding. Springs and foam, as well as other types of common cushioning materials, are prone to wear at the points of increased pressure. Over time, mattresses often wear in the location where a user rests their torso. Repeated use leaves an impression in the mattress. Once the impression is formed, the mattress must be replaced.

SUMMARY

An exemplary aspect of the present disclosure relates to a mattress and a method for manufacturing a mattress. The method includes, among other things, forming a batt of polymer fibers with a reduced dimension, forming a topper layer of polymer fibers having a lower surface corresponding to the reduced dimension in the batt, and arranging the topper layer relative to the batt such that the lower surface of the topper layer mates with the reduced dimension in the batt.

The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings can be briefly described as follows:

FIG. 1 is a highly schematic illustration of a system for providing a fiber batt with a reduced dimension.

FIG. 2 is a flow chart representative of an example method according to this disclosure.

FIG. 3 is a sectional view of a first example topper layer.

FIG. 4 is a sectional view of a first example mattress, and illustrates the manner in which the topper layer mates with the batt.

FIG. 5 is a sectional view of a second example topper layer.

FIG. 6 is top-perspective view of the second example topper layer.

FIG. 7 is a sectional view of a second example mattress.

DETAILED DESCRIPTION

FIG. 1 illustrates a highly schematic view of a system 10 for providing a fiber batt 12 with a reduced dimension 14. As used herein, the term “reduced dimension” refers to an area in the batt 12 having a dimension (such as height) less than that of the surrounding, adjacent area.

The batt 12 is combined with a topper layer 14 to provide a mattress M (FIG. 4). The mattress M may also include other layers such as cloth covering. In this example, the batt 12 is formed of loose polymer fibers 16 and a polymer binder. The loose fibers 16 are extruded in a continuous in-line process, as generally indicated by the arrows 18, and are heated to melt the binder between the fibers 16 to provide the batt 12. FIG. 2 illustrates a method 20. The step of forming the batt 12, discussed above, is represented at step 22.

In one example, the batt 12 includes a pre-impression formed by a roller 24. The pre-impression provides the reduced dimension 14 in this example. In this example, the roller 24 is configured to rotate about an axis 26. Further, the roller 24 may be raised and lowered in an up-and-down direction 28 perpendicular to the axis 26. In other examples, the roller 24 may also be movable side-to-side in a direction parallel to the axis 26. The step of providing the reduced dimension 14 by a pre-impression is illustrated in FIG. 2 at step 30A.

By raising and lowering the roller 24 in the direction 28, the pre-impression can be provided at select locations along the length of the batt 12. That is, the pre-impression may be formed to correspond to a location where a torso would be positioned when a user lays on a mattress including the batt 12. Alternatively, the pre-impression may extend the entire length of the batt 12.

The reduced dimension 14 does not need to be provided by a pre-impression (from the roller 24, for example). Instead, the reduced dimension 14 can be formed using another manufacturing technique such as cutting a block of polymer fibers or molding (including extruding through a tool) polymer fibers. This alternative approach is represented in FIG. 2 at 30B.

The reduced dimension 14 provides the batt 12 with a height H₁ at a center point. The height H₁ is less than a height H₂ at the outer, lateral sides 17, 19 of the batt 12. When formed by a pre-impression (e.g., by the roller 24), the density of the batt 12 at H₁ is within a range of 1.1-3.0 times greater than at the height H₂. In one example, the density of the batt 12 at H₁ is about 2.5 times greater than at the height H₂. This increased density resists deformation from repeated use.

In the instance where the reduced dimension 14 is machined (e.g., at step 30B), the density of the batt 12 is substantially consistent throughout. That is, the density of the batt 12 at H₁ at is substantially equal to density of the batt 12 at H₂.

With reference again to the method 20, the batt 12 is allowed to cool at step 32. At 34, a topper layer 36 is formed. The topper layer 36 may be formed by extrusion. In that case, the polymer material forming the topper layer 36 is drawn through a die having a shape corresponding to the shape of the topper layer 36 illustrated in FIG. 3.

The topper layer 36 includes a substantially planar upper surface 38 (see FIG. 3) parallel to a planar lower surface 43 (see FIG. 4) of the batt 12, and a lower surface 40 having a contour corresponding to the contour of an upper surface 42 of the batt 12. At a center point, is the topper layer 36 is provided with a height H₃ that is greater than a height H₄ at the lateral sides 45, 47. The height H₃ corresponds to the reduced height H₁ at the center point of the batt 12 provided by the reduced dimension 14.

The material of the topper layer 36 may be, in one example, a three-dimensional netted structure made of a plurality of polymer filaments that are helically and randomly entangled, and partially thermally bonded together. The topper layer 36 is resilient while also providing enhanced levels of comfort.

At 44, the topper layer 36 and the batt 12 are arranged such that the lower surface 40 of the topper layer 36 mates with the upper surface 42 of the batt 12. This arrangement is shown in FIG. 4. The increased height H₃ in the topper layer 36 provides increased padding at points where there may be a higher likelihood of wear due to use. Further, by having the increased density in the batt 12 at the same, central location, the mattress is resistant to deformation and provides increased support over a longer period of time. Even when the batt 12 does not have an increased density at the height H₁, the increased height of the topper layer 36 at H₃ still provides increased support and resists deformation from repeated use.

The topper layer 36 may be attached to the batt 12 by way of an adhesive. Alternatively the topper layer 36 and the batt 12 may be connected by tufting. Regardless of the type of connection between the topper layer 36 and the batt 12, the topper layer 36 and the batt 12 may be relatively easily separated for recycling, as represented at optional step 46.

The batt 12 and the topper layer 36 may be different materials, which cannot be recycled together. However, both materials are completely recyclable. Thus, after detaching the two structures, the topper layer 36 and the batt 12 can be separately recycled, which provides a completely recyclable product.

FIGS. 5 and 6 illustrate a second example topper layer 136 in which the topper layer 136 has customized densities along its length and/or width. To the extent not otherwise described or shown, the topper layer 136 corresponds to the topper layer 36 of FIG. 3, with like parts having reference numerals preappended with a “1.”

In the example of FIG. 5, the topper layer 136 has a width between opposed lateral sides 145 and 147. Adjacent the center point (i.e., between the lateral sides 145, 147), the topper layer 136 is provided by a first polymer blend, which provides the topper layer 136 with a first density across the width W₂. Adjacent the lateral sides 145, 147, the topper layer is provided by a second polymer blend, which provides the topper layer 136 with a second density across the widths W₁, W₃. The second density is less than the first density. The increased density in the center of the topper layer 136 resists deformation from use, as a user's torso is likely to rest near the center of the topper layer 136.

The increased density may also be customized relative to the length of the topper layer 136. In FIG. 6, the topper layer 136 has a front end 149 and a rear end 151. In one example, adjacent the center of topper layer 136, the topper layer 136 is provided by a first polymer blend across a center length L₂, which has an increased density relative to a second polymer blend provided across lengths L₁, L₃ adjacent the front and rear ends 149, 151. In one particular example, the topper layer 136 has an increased density zone 153 within the length L₂ and the width W₂. Alternatively, the topper layer 136 could have an increased density within the width W₂ and along the entire length (L₁, L₂, and L₃) of the topper layer 136, or the topper layer 136 could have an increased density within the length L₂ and across the entire width (W₁, W₂, and W₃) of the topper layer 136.

In order to customize the topper layer 136, which may be formed using an extrusion process, polymer fiber blends of different densities are selectively fed through a die, either manually or automatically, to provide the desired location of the increased density zone 153.

FIG. 7 illustrates a second example mattress M including a batt 212 and two topper layers 236A, 236B. In this example, the mattress M is a dual sided (sometimes called “double sided”) mattress, and resembles, in cross-section, the mattress M of FIG. 4 reflected about a horizontal axis H (extending between lateral sides 217, 219). To the extent not otherwise described or shown, the batt 212 and topper layers 236A, 236B correspond to the mattress M of FIG. 4, with like parts having reference numerals preappended with a “2.” In this example, both the upper surface 242 and the lower surface 243 of the batt 212 are contoured to match the contour of the inner surfaces 240A, 240B, respectively, of the upper and lower topper layers 236A, 236B. Further, the outer surfaces 238A, 238B are parallel to one another. The mattress M of FIG. 7 can include any of the features described above relative to FIGS. 1-6.

In general, the mattresses M disclosed in FIGS. 1-7 provide the ability to “tune,” or customize, the density of the mattress based on a particular application. Further, the above described mattresses M allow for enhanced comfort and performance.

Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples. Further, terms such as “generally,” “substantially,” and “about” are not intended to be boundaryless terms, and should be interpreted consistent with the way one skilled in the art would interpret the term. Further, terms such as “upper,” “lower,” “inner,” and “outer,” are used above with reference to the normal operational position of the mattress M. These terms have been used herein for purposes of explanation, and should not be considered otherwise limiting.

One of ordinary skill in this art would understand that the above-described embodiments are exemplary and non-limiting. That is, modifications of this disclosure would come within the scope of the claims. Accordingly, the following claims should be studied to determine their true scope and content. 

What is claimed is:
 1. A method for manufacturing a mattress, comprising: forming a batt of polymer fibers, the batt having at least one location with a reduced dimension; forming a topper layer of polymer fibers having a surface corresponding to the reduced dimension in the batt; and arranging the topper layer relative to the batt such that the surface of the topper layer mates with the reduced dimension in the batt.
 2. The method as recited in claim 1, wherein the reduced dimension provides the batt with a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height less than the second height.
 3. The method as recited in claim 2, wherein the batt has a consistent density throughout.
 4. The method as recited in claim 2, wherein the reduced dimension is provided by a pre-impression, and wherein the batt has a first density at the first height and a second density at the second height, the first density greater than the second density.
 5. The method as recited in claim 4, wherein the first density is within a range of 1.1-3.0 times greater than the second density.
 6. The method as recited in claim 5, wherein the first density is about 2.5 times greater than the second density.
 7. The method as recited in claim 1, wherein the topper layer is provided by a three-dimensional netted polymer structure.
 8. The method as recited in claim 7, wherein the three-dimensional netted polymer structure includes a plurality of randomly entangled polymer filaments, the polymer filaments being partially thermally bonded together.
 9. The method as recited in claim 1, wherein the topper layer has a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height greater than the second height.
 10. The method as recited in claim 9, wherein the topper layer has a first density at the first height and a second density at the second height, the first density greater than the second density.
 11. The method as recited in claim 1, wherein the density of the topper layer varies along at least one of a width and a length.
 12. The method as recited in claim 1, wherein an upper surface of the topper layer is parallel to a lower surface of the batt, and wherein a lower surface of the topper layer is contoured to correspond to the reduced dimension in the batt.
 13. The method as recited in claim 1, further comprising: forming a first topper layer of polymer fibers having a surface corresponding to the reduced dimension in the batt; forming a second topper layer of polymer fibers having a surface corresponding to the reduced dimension in the batt; and arranging the first topper layer adjacent an upper surface of the batt and the second topper layer adjacent the lower surface of the batt such that the surfaces of the first and second topper layers mate with the reduced dimension in the batt.
 14. A method for manufacturing a mattress, comprising: extruding loose polymer fibers; heating the extruded polymer fibers; and providing the extruded polymer fibers with a reduced dimension at at least one location.
 15. The method as recited in claim 14, wherein the reduced dimension provides the extruded polymer fibers with a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height less than the second height.
 16. The method as recited in claim 15, wherein the extruded polymer fibers have a first density at the first height and a second density at the second height, the first density greater than the second density.
 17. The method as recited in claim 14, further comprising: mating a topper layer with the extruded polymer fibers, the topper layer having a contour corresponding to the reduced dimension.
 18. The method as recited in claim 17, further comprising: separating the topper layer from the extruded polymer fibers; and separately recycling the topper layer and the extruded polymer fibers.
 19. A mattress, comprising: a batt of polymer fibers, the batt having an upper surface, a lower surface, and opposed lateral sides, wherein the upper surface has a contour providing the batt with a reduced dimension, the reduced dimension providing the batt with a first height at a center point between the opposed lateral sides and a second height at the lateral sides, the first height less than the second height; and a topper layer of polymer fibers having an upper surface, a lower surface, and opposed lateral sides, the lower surface having a contour corresponding to the reduced dimension in the batt, the topper layer arranged relative to the batt such that the lower surface of the topper layer mates with the reduced dimension in the batt.
 20. The mattress as recited in claim 19, wherein: the topper layer has a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height greater than the second height; and the topper layer has a first density at the first height and a second density at the second height, the first density greater than the second density. 